Processes for producing a fuel from a renewable feedstock

ABSTRACT

Processes for the production of transportation fuel from a renewable feedstock. A gaseous mixture of carbon monoxide and hydrogen is used to deoxygenate and hydrogenate the glycerides to produce long chain hydrocarbons. Water is also introduced into the reaction zone to increase the amount of hydrogen and to increase the utilization of carbon monoxide within the reaction zone. Synthesis gas may also be used to supply at least a portion of the gaseous mixture of carbon monoxide and hydrogen. The amount of hydrogen equivalents in the reaction zone is at least 100% of a stoichiometric hydrogen demand within the reaction zone.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from Provisional Application No. 62/200,843 filed Aug. 4, 2015, the contents of which are hereby incorporated by reference.

FIELD OF THE INVENTION

This invention relates generally to processes for the conversion of oils from a renewable feedstock to diesel fuel and more particularly to processes which minimize the consumption of high purity hydrogen in such processes.

BACKGROUND OF THE INVENTION

The use of biofuels is becoming more and more popular around the world especially based upon concerns from limited petroleum resources, increasing energy demand, greenhouse gas emissions and related climate change concerns. In addition to producing petroleum derived fuels, the fuels can also be manufactured using carbon and hydrogen derived from organic biomass, such as vegetable oils, organic fats, and organic greases.

For example, biological oils and fats can be converted into diesel, naphtha and jet fuels using many different processes, such as hydro-deoxygenation, decarboxylation, decarbonylation, and hydro-isomerization processes. Diesel fuel refers to a mixture of carbon chains that generally contain between 8 and 21 carbon atoms per molecule. Typically, diesel has a boiling point in the range of 180 to 380° C. (356 to 716° F.). The production of diesel fuel can be either petroleum-derived or biologically-sourced. Petroleum-derived diesel is produced from the fractional distillation of crude oil, refining products, or by conversion processes. On the other hand, biologically-sourced diesel fuel is derived from renewable feedstock, such as vegetable oils or animal fats.

The biologically-sourced diesel fuel is desirable for a variety of reasons. In addition to the ecological benefits of using biologically-sourced diesel fuel, there exists a market demand for such fuel. For diesel purchasers, the use of biologically-sourced diesel fuel can be promoted in public relations. Also, certain governmental policies may require or reward use of biologically-sourced fuels. Finally, fluctuation of crude oil prices is also a reason refiners may choose to produce biologically-sourced fuels. The biologically-sourced diesel fuel is usually classified into two categories, biodiesel and green diesel.

Biodiesel (also referred to as fatty acid methyl ester, or FAME) mainly consists of long-chain alkyl esters typically mono-alkyl ester products derived from a lipid feedstock. The chemical structure of biodiesel is distinctly different from petroleum-derived diesel, and therefore biodiesel has somewhat different physical and chemical properties from petroleum-derived diesel. For example, biodiesel has a much higher oxygen content than petroleum-derived diesel.

Green diesel (also referred to as renewable hydrocarbon diesel, hydroprocessed vegetable oils or HVO), on the other hand, is substantially the same chemically as petroleum-derived diesel, but green diesel is made from recently living biomass. Unlike biodiesel, which is an ester and has different chemical properties from petroleum diesel, green diesel is composed of long-chain hydrocarbons, and can be mixed with petroleum diesel in any proportion for use as transportation fuel. Green diesel resembles petroleum-derived diesel fuel and usually has a very low heteroatom (nitrogen, oxygen, sulfur) content. Green diesel can thus be produced to be indistinguishable from petroleum diesel. This is beneficial because no changes to fuel infrastructure or vehicle technology are required for green diesel and it may be blended in any proportion with petroleum-derived diesel fuel as it is stable, not oxygenated. Further, unlike FAME biodiesel technology which produces glycerin as a by-product, the production of green diesel generates valuable co-products like naphtha, liquefied petroleum gas components like propane and butane, and fuel gases like methane and ethane.

The production of green diesel from some biomasses, such as vegetable oils, consumes large amounts of hydrogen. In some areas, hydrogen is not abundantly available and therefore, reactions that require large amounts of hydrogen may be economically unviable. However, even if areas in which hydrogen is available, the required hydrogen is an added cost for a refiner. In addition to having high hydrogen demands, the decarboxylation, decarbonylation, and hydrodeoxygenation reactions associated with converting the triglycerides found in the oils into paraffins typically produce large amounts of water. Water can be a poison for many isomerization catalysts, such as the catalysts typically used to upgrade the cold flow properties of a diesel fuel.

Therefore, it would be desirable to have one or more processes that allow for effective and efficient conversion of triglycerides into paraffins which have a lower hydrogen demand. Furthermore, it would also be desirable to provide processes which increase the in situ hydrogen generation within the reaction zone.

SUMMARY OF THE INVENTION

One or more processes have been invented for producing a transportation fuel from a biomass oil in which carbon monoxide is used as a reducing agent along with hydrogen. By utilizing carbon monoxide, the amount of hydrogen necessary for the conversion reactions is lowered, and the inclusion of some hydrogen will ensure proper saturation of any double bonds. Further, the amount of hydrogen is further increased by injecting water into the reaction zone. The water, via the water gas shift reaction, will react with carbon monoxide to produce hydrogen gas.

In a first embodiment of the invention, the present invention may be characterized broadly as providing a process for converting a renewable feedstock to a transportation fuel by: deoxygenating a renewable feedstock in a reaction zone having a catalyst; passing a gaseous stream to the reaction zone, wherein the gaseous stream comprises a mixture carbon monoxide and hydrogen; and, passing water into the reaction zone to promote deoxygenation and to produce hydrogen.

In various embodiments of the present invention, the water is passed into the reaction zone by mixing a stream comprising water with the renewable feedstock to form a combined feed stream that is passed into the reaction zone. It is contemplated that the water comprises steam.

In one or more embodiments of the present invention, the process further comprises heating water to provide a high pressure steam, which is passed into the reaction zone. It is contemplated that the high pressure steam is combined with the renewable feedstock before the high pressure steam is passed into the reaction zone.

In at least one embodiment of the present invention, an amount of hydrogen equivalents in the reaction zone comprises at least 100% of a stoichiometric hydrogen demand within the reaction zone.

In at least one embodiment of the present invention, an amount of hydrogen equivalents in the reaction zone comprises at least 125% of a stoichiometric hydrogen demand within the reaction zone.

In at least one embodiment of the present invention, an amount of hydrogen equivalents in the reaction zone comprises at least 150% of a stoichiometric hydrogen demand within the reaction zone.

In at least one embodiment of the present invention, the gaseous stream comprises syngas.

In a second aspect of the present invention, the present invention may be generally characterized as providing a process for converting a renewable feedstock to a transportation fuel by: passing a renewable feedstock into a deoxygenation zone having a vessel with a catalyst and being configured to deoxygenate oxygenated hydrocarbons; passing a gaseous stream to the deoxygenation zone, wherein the gaseous stream comprises a mixture carbon monoxide and hydrogen; passing a water stream into the deoxygenation zone to promote deoxygenation and to produce hydrogen; and, recovering an effluent stream from the deoxygenation zone.

In at least one embodiment of the present invention, the molar ratio of hydrogen to carbon monoxide to water in the deoxygenation zone is approximately 1:1:0.9.

In at least one embodiment of the present invention, an amount of hydrogen equivalents in the deoxygenation zone comprises at least 100% of a stoichiometric hydrogen demand within the deoxygenation zone.

In at least one embodiment of the present invention, an amount of hydrogen equivalents in the deoxygenation zone comprises between about 125 and 180% of a stoichiometric hydrogen demand within the deoxygenation zone.

In various embodiments of the present invention, the process includes heating a stream of water to provide a high pressure steam, wherein the high pressure steam is passed to the deoxygenation zone. It is contemplated that the high pressure steam is combined with the renewable feedstock before being passed into the deoxygenation zone.

In some embodiments of the present invention, the process includes generating a syngas stream and passing at least a portion of the syngas stream to the deoxygenation zone as the gaseous stream.

In various embodiments of the present invention, the molar ratio of hydrogen to carbon monoxide of the gaseous stream comprises between 50:50 to 80:20.

In one or more embodiments of the present invention, at least a portion of the gaseous stream is combined with the renewable feedstock before being passed into the deoxygenation zone. It is contemplated that at least a portion of the gaseous stream is injected directly into the deoxygenation zone. It is also contemplated that a high pressure steam is combined with the renewable feedstock before being passed into the deoxygenation zone.

Additional aspects, embodiments, and details of the invention, all of which may be combinable in any manner, are set forth in the following detailed description of the invention

BRIEF DESCRIPTION OF THE DRAWINGS

One or more exemplary embodiments of the present invention will be described below in conjunction with the following drawing figures, in which:

FIG. 1 shows a process flow diagram according to one or more embodiments of the present invention; and,

FIG. 2 shows another process flow diagram of one or more embodiments of the present invention

DETAILED DESCRIPTION OF THE INVENTION

As mentioned above, the present invention provides one or more processes for producing a transportation fuel, such as diesel fuel, from renewable sources. These renewable sources include, but are not limited to, plant oils such as corn, rapeseed, canola, soybean and algal oils, animal fats such as tallow, fish oils and various waste streams such as yellow and brown greases, dairy sludge, used or recycled cooking oil, by-products from edible oil refining such as palm stearin or palm fatty acid distillate or recovered oils from spent bleaching earth, and sewage sludge. The common feature of these sources is that they are composed of glycerides and Free Fatty Acids (FFA). Both of these classes of compounds contain aliphatic carbon chains having from 8 to 24 carbon atoms. The aliphatic carbon chains in the glycerides or FFAs can be saturated or mono-, di- or poly-unsaturated. The term renewable feedstock is meant to include feedstocks other than those derived from petroleum crude oil. The renewable feedstocks that can be used in the present invention include any of those which comprise glycerides and FFAs. Most of the glycerides will be triglycerides, but monoglycerides and diglycerides may be present and processed as well. Examples of these renewable feedstocks include, but are not limited to, canola oil, corn oil, soy oils, rapeseed oil, soybean oil, colza oil, tall oil, sunflower oil, hempseed oil, olive oil, linseed oil, coconut oil, castor oil, peanut oil, palm oil, mustard oil, tallow, yellow and brown greases, lard, train oil, fats in milk, fish oil, algal oil, sewage sludge lipids, and the like. Additional examples of renewable feedstocks include non-edible vegetable oils from the group comprising Jatropha curcas (Ratanjoy, Wild Castor, Jangli Erandi), Madhuca indica (Mohuwa), Pongamia pinnata (Karanji Honge), and Azadirachta indicia (Neem). The glycerides and FFAs of the typical vegetable or animal fat contain aliphatic hydrocarbon chains in their structure which have 8 to 24 carbon atoms with a majority of the fats and oils containing high concentrations of fatty acids with 16 and 18 carbon atoms.

Vegetable oils are long chain esters of fatty acids with glycerol. Three main reactions are involved in producing the n-paraffin in presence of hydrogen for jet/diesel production are:

(Decarboxylation) C_(n)H_(2n+1)COOR+H₂=C_(n)H_(2n+2)+CO₂+RH;

(Decarbonylation) C_(n)H_(2n+1)COOR+2H₂=C_(n)H_(2n+2)+CO+H₂O+RH; and,

(Hydrodeoxygenation) C_(n)H_(2n+1)COOR+4H₂=C_(n+1)H_(2(n+2))+2H₂O+RH.

Over and above these three key reactions, any double bonds present in the fatty acid chains also undergo hydrogenation to produce saturated fatty acid chains.

As will be appreciated from the reactions above, the decarbonylation and hydrodeoxygenation reactions consume a significant portion of the hydrogen for the conversion of the fatty acids in glycerides. Additionally, these reactions produce water which may act as a poison for certain downstream catalysts. In contrast to hydrogen, it is known to use carbon monoxide as a reducing agent to remove oxygen atoms from the fatty acids in glycerides. See, EP 2 177 587. While the carbon monoxide may function to remove the oxygen atoms from the fatty acids, the lack of hydrogen will result in the production of unsaturated hydrocarbons. This can lead the oligomerization and adversely impact product quality and foul production lines. However, it has been discovered that processes to produce transportation fuel from a renewable resource can utilize a mixture of hydrogen and carbon monoxide to convert the components of a renewable feedstock to transportation fuel. In addition to requiring less hydrogen, the processes will produce minimal amounts of water. The water, via the water gas shift reaction, can react with the produced or supplied carbon monoxide to further produce hydrogen. Accordingly, in various aspects of the present invention, water is also injected into the reaction zone.

With these general principles in mind, one or more embodiments of the present invention will be described with the understanding that the following description is not intended to be limiting.

As shown in FIG. 1, a renewable feedstock 10 is passed to a first reaction zone 12 comprising one or more catalyst beds in one or more reactors 14. The term “feedstock” is meant to include feedstocks that have not been treated to remove contaminants as well as those feedstocks purified in a pretreatment zone (not shown). The feedstock 10 is preferably heated, for example in a heat exchanger 16, prior to entering the reactor 14. Additionally, the feedstock 10 may be combined with a partially unconverted stream 10 a (discussed below) to form a combined feedstock 10 b.

In addition to the feedstock 10, a gaseous stream 18 is also passed to the reactor 14 of the first reaction zone 12. The gaseous stream 18 comprises a mixture of carbon monoxide and hydrogen. The gaseous stream 18 may comprise one or more recycle gas streams (discussed below) as well as a makeup stream 19 from a source of carbon monoxide and hydrogen. The makeup stream 19 may comprise synthesis gas. The synthesis gas may be obtained from the gasification of coal or coke or from the steam reforming of methane or naphtha. Additionally and alternatively, the synthesis gas may be obtained from the gasification of biomass, including municipal solid waste, plant residues from agriculture or forestry or aquatic organisms. However, as such a process produces nitrogen gas, it is unknown what, if any, impact the nitrogen will have, for example, forming ammonia in the system. Therefore, it is preferable that the synthesis gas is nitrogen free. This may be accomplished by biomass catalyst partial oxidation or by air separation to remove nitrogen upstream of the gasifier.

Another potential source of carbon monoxide and hydrogen for the gaseous stream 18 is from a steel production processes which typically dispose of large volumes of specialty gases. In steel production, three different process stages, from coal to steel, provide three different gas types: coke gas, blast furnace gas and converter gas. Coke gas comprises between 50 to 70 mol % hydrogen, 25 to 30 mol % methane, 10 to 20 mol % of carbon monoxide, and small amounts of carbon dioxide and nitrogen. Blast furnace gas comprises about 20 mol % carbon monoxide and about 5 mol % hydrogen. Converter gas comprises about 65 mol % carbon monoxide with small amount of hydrogen, 15 mol % carbon dioxide, and 15 mol % nitrogen. Another potential source of carbon monoxide and hydrogen is from an FCC off-gas and a refinery off-gas stream. Both of these streams may have carbon monoxide and hydrogen.

Additionally, yet another source of carbon monoxide and hydrogen for gaseous stream 18 may be a refinery gas stream such as a stream from downstream of a reformer and upstream of a shift reactor. Typically such gas comprises about 70% hydrogen and 20% carbon monoxide and the balance of carbon dioxide and methane. Such a gas may require acid gas/nitrogen gas removal. In addition to the preferred removal of nitrogen gas and even though carbon dioxide is inert, the effect of the carbon dioxide on the catalyst is unclear. Accordingly, it is preferred that the gas is treated to remove carbon dioxide or at least that a portion of the gas is purged to reduce the amount, and thus the partial pressure, of inert gas molecules to be lowered. Utilizing an off gas or gas stream from such refinery processes is beneficial because such streams are readily available and cost effective source of the gaseous stream in the processes of the present invention. Additionally the utilization of such a gaseous stream will minimize the amount of gas passed to a PSA unit. Indeed, as the present invention utilizes a gaseous stream having a mixture of hydrogen and carbon monoxide, there is no need to obtain pure (i.e., >99.999% hydrogen) gas.

Additionally, a stream of water 17 is also passed into the first reaction zone 12. Although it is depicted as mixing with the combined feedstock 10 b, which is then passed into the first reaction zone 12, the stream of water 17 may be directly injected into the first reaction zone 12. The stream of water 17 may comprise liquid water, such as deionized water, or it may comprise a high pressure steam that is generated by heating liquid water. It is also contemplated that the stream of water 17 and the gaseous stream 18 are combined, and may comprise, for example, a gaseous stream from a reforming reactor or shift reactor, as these gaseous streams as considerable amounts of steam, carbon monoxide, and hydrogen. Any carbon dioxide is preferably removed using known processes.

Due to the formation of hydrogen by the water from both the deoxygenation reactions and that is injected via the stream of water 17, it is preferred that the amount of hydrogen equivalents within the first reaction zone 12 comprises at least 100%, or at least 125% or at least 150%, of the stoichiometric hydrogen demand. The phrase hydrogen equivalents refers to the moles of hydrogen gas (H₂) and moles of water (H₂O)—since part of the hydrogen used in the reactions is generated by the water gas shift reaction. Most preferably, the amount of hydrogen equivalents within the first reaction zone 12 comprises between 125 and 180% of the stoichiometric hydrogen demand.

Additionally, a molar ratio of hydrogen to carbon monoxide to water within the reaction zone is approximately 1:1:0.9. However, other ratios may be utilized.

Returning to FIG. 1, in the first reaction zone 12, the feedstock 10 is contacted with a hydrogenation or hydrotreating catalyst in the presence of hydrogen and carbon monoxide at hydrogenation conditions to hydrogenate the olefinic or unsaturated portions of the n-paraffinic chains and deoxygenate the oxygenated hydrocarbons.

Hydrogenation conditions include a temperature of 100 to 500° C. (212 to 932° F.) and a pressure of 689 kPa absolute (100 psia) to 13,790 kPa absolute (2000 psia). In another embodiment the hydrogenation conditions include a temperature of 200 to 300° C. (392 to 572° F.) and a pressure of 1379 kPa absolute (200 psia) to 4,826 kPa absolute (700 psia). Other operating conditions for the hydrogenation zone are well known in the art.

Hydrogenation or hydrotreating catalysts are any of those well known in the art such as nickel, nickel/molybdenum, cobalt/molybdenum dispersed on a high surface area support. Other hydrogenation or hydrotreating catalysts include one or more noble metal catalytic elements dispersed on a high surface area support. Non-limiting examples of noble metals include Pt and/or Pd dispersed on gamma-alumina. These hydrogenation or hydrotreating catalysts are also capable of catalyzing decarboxylation and/or deoxygenation of the feedstock to remove oxygen from the gylcerols.

It is preferred that the catalyst is sulfided. Triglycerides, being low on sulfur, may cause leaching of sulfur from sulfided catalyst and the high oxygen content could damage the sulfide structure of the catalyst. Additionally, studies have revealed that poly-condensation products formed have shortened the life by deactivation. Accordingly, in order to maintain the catalyst in a partially sulfided state, sulfur may be added to the feedstock 10 or may be introduced into the reactor 14 separately from the feedstock 10.

Generally, decarboxylation and/or deoxygenation conditions include a pressure of 3,447 kPa (500 psia) to 13,790 kPa (2,000 psia), a temperature of 200 to 400° C. (392 to 752° F.) and a liquid hourly space velocity of 0.5 to 10 hr⁻¹. In another embodiment the decarboxylation conditions include the same pressure of 3,447 kPa (500 psia) to 13,790 kPa (2,000 psia), a temperature of 288 to 345° C. (550 to 653° F.) and a liquid hourly space velocity of 1 to 4 hr⁻¹.

Since the hydrogenation of the double bonds in the fatty acid chains of the triglycerides is an exothermic reaction, as the feedstock 10 flows through the catalyst bed the temperature increases and decarboxylation and deoxygenation may begin to occur. Thus, it is envisioned and is within the scope of this invention that all the reactions occur simultaneously in one reactor or in one bed. Alternatively, the conditions can be controlled such that hydrogenation primarily occurs in one bed and decarboxylation and/or deoxygenation occurs in a second bed. Of course if only one bed is used, then hydrogenation occurs primarily at the front of the bed, while decarboxylation/deoxygenation occurs mainly in the middle and bottom of the bed. Finally, desired hydrogenation can be carried out in one reactor, while decarboxylation and/or deoxygenation can be carried out in a separate reactor.

Returning to FIG. 1, an effluent 20 from the first reaction zone 12 is introduced to a separation zone 21 having a phase separator 22. Hydrogen, carbon oxides, possibly hydrogen sulfide and C₃-hydrocarbons are separated and removed in line 24 and liquid hydrocarbons are removed in line 26. Water may also be removed from the phase separator 22 in a line 28. Alternatively, although not depicted as such, the water may be removed as a vapor in line 24.

Since the vapor in line 24 from the phase separator 22 comprises a large quantity of hydrogen and carbon monoxide it may be used as a recycle gas stream. The carbon dioxide in the vapor in line 24 can be removed from the hydrogen and carbon monoxide in a scrubbing zone 30. The scrubbing zone 30 may comprise any well-known systems in the art, such as reaction with a hot carbonate solution, pressure swing adsorption, absorption with an amine in processes, etc. If desired, essentially pure carbon dioxide can be recovered by regenerating the spent absorption media. Thus, the vapor in line 24 is passed through one or more scrubbing zones 30 to remove carbon dioxide and hydrogen sulfide and provide a scrubbed recycle gas 32. The scrubbed recycle gas 32 will comprise the C₃-hydrocarbons, hydrogen, and carbon monoxide and may be compressed in a recycle gas compressor 34 and used as a recycle gas stream form a portion of the gaseous stream 18. Additionally, a portion of the scrubbed recycle gas may be utilized to isomerize hydrocarbons (discussed below) and can be from a suction or discharge of the recycle gas compressor 34. Furthermore, it is contemplated that a portion of the scrubbed recycled gas is passed back to the reactor 14 in the reaction zone 12 as a quench fluid in line 33 to control the temperature in the reactor 14.

Returning to the phase separator 22, the liquid hydrocarbons removed from the phase separator 22 in line 26 will have poor cold flow properties because it comprises essentially normal paraffins. In order to improve the cold flow properties of the liquid hydrocarbon fraction, the liquid hydrocarbons in line 26 can be passed to an isomerization zone 36. As will be appreciated, the isomerization zone 36 comprises one or more reactors 38 which contain an isomerization catalyst and which are operated under isomerization conditions to at least partially isomerize the normal paraffins to branched paraffins. Additionally, a hydrogen containing gas 40 is also passed to the isomerization zone 36, and as mentioned above, the hydrogen containing gas 40 may comprise a portion of the scrubbed recycle gas 32.

In the isomerization zone 36, only minimal branching of the hydrocarbons is required, enough to overcome cold-flow problems of the normal paraffins. Since attempting for significant branching runs the risk of high degree of undesired cracking, the predominant isomerized product is a mono-branched hydrocarbon. An isomerized effluent 42 of the isomerization zone 36 comprises a branched-paraffin-rich stream. By the term “rich” it is meant that the isomerized effluent 42 has a greater concentration of branched paraffins than the hydrocarbons entering the isomerization zone 36, and preferably comprises greater than 50 mole % branched paraffins. It is envisioned that the isomerized effluent 42 comprises 70, 80, or 90 mole % branched paraffins.

The isomerization of the liquid hydrocarbons in line 26 can be accomplished in any manner known in the art or by using any suitable catalyst known in the art. One or more beds of catalyst may be used within the reactor(s) 38 in the isomerization zone 36. It is preferred that the isomerization be operated in a co-current mode of operation. Fixed bed, trickle bed down flow or fixed bed liquid filled up-flow modes are both suitable. See also, for example, US 2004/0230085. Suitable catalysts comprise a metal of Group VIII (IUPAC 8-10) of the Periodic Table and a support material. Suitable Group VIII metals include platinum and palladium, each of which may be used alone or in combination. The support material may be amorphous or crystalline. Suitable support materials may include amorphous alumina, amorphous silica-alumina, ferrierite, ALPO-31, SAPO-11, SAPO-31, SAPO-37, SAPO-41, SM-3, MgAPSO-31, FU-9, NU-10, NU-23, ZSM-12, ZSM-22, ZSM-23, ZSM-35, ZSM-48. ZSM-50, ZSM-57, MeAPO-I 1, MeAPO-31, MeAPO-41, MeAPSO-I 1, MeAPSO-31, MeAPSO-41, MeAPSO-46, ELAPO-I1, ELAPO-31, ELAPO-41, ELAPSO-I1, ELAPSO-31, ELAPSO-41, laumontite, cancrinite, offretite, hydrogen form of stillbite, magnesium or calcium form of mordenite, and magnesium or calcium form of partheite, each of which may be used alone or in combination. ALPO-31 is described in U.S. Pat. No. 4,310,440. SAPO-11, SAPO-31, SAPO-37, and SAPO-41 are described in U.S. Pat. No. 4,440,871. SM-3 is described in U.S. Pat. No. 4,943,424; U.S. Pat. No. 5,087,347; U.S. Pat. No. 5,158,665; and U.S. Pat. No. 5,208,005. MgAPSO is a MeAPSO, which is an acronym for a metal aluminumsilicophosphate molecular sieve, where the metal Me is magnesium (Mg). Suitable MeAPSO-31 catalysts include MgAPSO-31. MeAPSOs are described in U.S. Pat. No. 4,793,984, and MgAPSOs are described in U.S. Pat. No. 4,758,419. MgAPSO-31 is a preferred MgAPSO, where 31 means a MgAPSO having structure type 31. Many natural zeolites, such as ferrierite, that have an initially reduced pore size can be converted to forms suitable for olefin skeletal isomerization by removing associated alkali metal or alkaline earth metal by ammonium ion exchange and calcination to produce the substantially hydrogen form, as taught in U.S. Pat. No. 4,795,623 and U.S. Pat. No. 4,924,027. Further catalysts and conditions for skeletal isomerization are disclosed in U.S. Pat. No. 5,510,306, U.S. Pat. No. 5,082,956, and U.S. Pat. No. 5,741,759.

The isomerization catalyst may also comprise a modifier selected from the group consisting of lanthanum, cerium, praseodymium, neodymium, samarium, gadolinium, terbium, and mixtures thereof, as described in U.S. Pat. No. 5,716,897 and U.S. Pat. No. 5,851,949. Other suitable support materials include ZSM-22, ZSM-23, and ZSM-35, which are described for use in dewaxing in U.S. Pat. No. 5,246,566 and in the article entitled “New molecular sieve process for lube dewaxing by wax isomerization,” written by S. J. Miller, in Microporous Materials 2 (1994) 439-449.

Isomerization conditions may include a temperature between 200 to 400° C. (392 to 752° F.) and a pressure between 1724 kPa absolute (250 psia) to 4,726 kPa absolute (700 psia). In another embodiment the isomerization conditions include a temperature between 300 to 360° C. (572 to 680° F.) and a pressure between 3,102 kPa absolute (450 psia) to 3,792 kPa absolute (550 psia). Other operating conditions for the isomerization zone are well known in the art.

The isomerized effluent 42 may be passed to a separator vessel 44 to separate liquids and vapor, with the vapor being withdrawn in a line 46 and the liquid being withdrawn in a line 48. As the vapor in line 46 may comprise hydrogen and carbon monoxide, it may passed as a recycle gas stream to scrubbing zone(s) 30 (discussed above) which provide the scrubbed recycle gas 32. Although it is depicted that the two recycle gas streams are combined, this is merely a preferred embodiment.

The liquid 48 from the separator vessel 44 can be passed to a fractionation zone 50 having one or more fractionation columns 52 to separate one or more transportation fuels streams 54 from a bottoms stream 56. Additionally, other streams may likewise be withdrawn from the fractionation column(s) 52, including for example, a naphtha stream, propane, butane, pentane, and LPG streams to name a few.

The transportation fuel stream 54 preferably comprises a side draw stream from the fractionation column 52 and in most preferred embodiment comprises a diesel boiling range fuel stream. The bottoms stream 56 from the fractionation column 52 may comprise partially converted and/or some unconverted glycerides. Thus, the bottoms stream may be fed to reaction zone 12 as the partially unconverted stream 10 a (discussed above). Additionally, a portion of the bottoms stream 56 from the fractionation column 52 may also be used as cool quench liquid between beds of one of the reaction zone 12 to further control the heat of reaction and provide quench liquid for emergencies. The recycle stream may be introduced to the inlet of one the reaction zone 12 and/or to any subsequent beds or reactors. One benefit of the hydrocarbon recycle is to control the temperature rise across the individual beds.

With reference to FIG. 2, another embodiment of the present invention is shown, in which the fractionation zone 50 is disposed between the phase separator 22 of the separation zone 21 and the isomerization zone 36.

In this embodiment, the liquid hydrocarbons in line 26 are passed first to the fractionation zone 50 in which one or more columns 52 will separate the liquid hydrocarbons into a heavy effluent 60 and a light effluent 62. The heavy effluent 60 will comprise some unconverted feed and therefore may be used as a quench fluid, as a partially unconverted stream 10 a or both, similar to the bottoms stream 56 discussed above in regards to FIG. 1.

The light effluent 62 comprises diesel range hydrocarbons and lighter compounds. Thus, a stream of the light effluent 62 is passed to the isomerization zone 36 to improve the cold flow properties of the diesel range hydrocarbons. The isomerization zone 36 is described in detail above with respect to the embodiments shown in FIG. 1. One particular benefit of this process is that the size of the isomerization reactor can be smaller since the partially converted/unconverted oil is removed prior to isomerization. Additionally, the lower volume of liquid will lower operating costs of equipment, like pumps, associated with the transporting the liquid.

From the isomerization zone 36, the isomerized effluent 42 can be passed to the separator vessel 44 in which the isomerized effluent 42 will separate with the vapor being withdrawn in the line 46 and the liquid being withdrawn in the line 48. The gaseous component in line 46 can be used as a recycle gas stream as discussed above. The liquid in line 48 may comprise the desired transportation fuel, preferably, a diesel boiling range fuel. Additionally, other streams may be separated from either the gaseous component or the liquid component, such as, a naphtha, propane, butane, pentane, or LPG stream to name a few.

Experimental Examples

Various experimental examples were conducted using a feed, derived from soybean oil, consisting of a triglyceride having approximately 11% by mass C₁₆ fatty acids and approximately 84% by mass C₁₈ fatty acids with a cobalt/molybdenum catalyst. The reactor pressure was 10.34 MPa (1,500 psig) and a temperature of 300° C. (572° F.) was utilized.

TABLE 1 Experiment 1 2 3 4 5 6 7 Hours 3 3 4 3 3 6 5 Molar H₂ (H₂ + H₂O) 143 153 132 97 165 95 128 % of stoichiometric requirement Triglyceride 100 100 100 100 100 100 100 Conversion (%) C4-C14 Lights Yield 1 0 1 2 1 1 2 (mol %) C15-C18 Yield 93 94 93 44 75 97 80 (mol %) C15-C18 Oxygenates 6 5 6 54 24 2 18 and Other C19 + Heavies Yield (mol %) wt % Oxygen in <0.3 <0.3 <0.3 4.5 1.1 0.3 0.2 Product (Feed = 7.3) C18/C18 + C17 (%) 87 88 88 88 89 64 89 C16/C16 + C15 (%) 88 88 89 90 91 67 91

In Experiments 1 to 3, the feed included pure hydrogen, whereas in Experiments 4 to 7, a 1:1:0.9 molar ratio of hydrogen to carbon monoxide to water was included in the feed. As should be appreciated the mixed hydrogen, carbon monoxide and water experiments demonstrated comparable results compared to the pure hydrogen experiments.

Experiment 6 had a longer run time which caused the cracking of larger hydrocarbons, hence lowering the selectivity. This was confirmed by comparison to experiment 4. Experiment 5 utilized a comparable hydrogen stoichiometric amount present in the pure hydrogen examples. Except for experiment 6, the amount of carbon loss in the experiments with carbon monoxide and water was comparable to the hydrogen experiments. It is contemplated that further improvement may be realized by lowering the LHSV (with more catalyst). Furthermore, pressure and hydrogen supply was not constant in these experiments. Accordingly, improvement is expected in more controlled conditions.

Based upon the foregoing, the introduction of water into the reaction zone can produce additional hydrogen in situ—reducing the amount of external hydrogen required.

It should be appreciated and understood by those of ordinary skill in the art that various other components such as valves, pumps, filters, coolers, etc. were not shown in the drawings as it is believed that the specifics of same are well within the knowledge of those of ordinary skill in the art and a description of same is not necessary for practicing or understanding the embodiments of the present invention.

Specific Embodiments

While the following is described in conjunction with specific embodiments, it will be understood that this description is intended to illustrate and not limit the scope of the preceding description and the appended claims.

A first embodiment of the invention is a process for converting a renewable feedstock to a transportation fuel, the process comprising deoxygenating a renewable feedstock in a reaction zone having a catalyst, passing a gaseous stream to the reaction zone, wherein the gaseous stream comprises a mixture carbon monoxide and hydrogen, and, passing water into the reaction zone to promote deoxygenation and to produce hydrogen. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the water is passed into the reaction zone by mixing a stream comprising water with the renewable feedstock to form a combined feed stream that is passed into the reaction zone. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the water comprises steam. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph further comprising heating water to provide a high pressure steam; which is passed into the reaction zone. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the high pressure steam is combined with the renewable feedstock before the high pressure steam is passed into the reaction zone. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein an amount of hydrogen equivalents in the reaction zone comprises at least 100% of a stoichiometric hydrogen demand within the reaction zone. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein an amount of hydrogen equivalents in the reaction zone comprises at least 125% of a stoichiometric hydrogen demand within the reaction zone. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein an amount of hydrogen equivalents in the reaction zone comprises at least 150% of a stoichiometric hydrogen demand within the reaction zone. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the gaseous stream comprises syngas.

A second embodiment of the invention is a process for converting a renewable feedstock to a transportation fuel, the process comprising passing a renewable feedstock into a deoxygenation zone having a vessel with a catalyst and being configured to deoxygenate oxygenated hydrocarbons; passing a gaseous stream to the deoxygenation zone, wherein the gaseous stream comprises a mixture carbon monoxide and hydrogen; passing a water stream into the deoxygenation zone to promote deoxygenation and to produce hydrogen; and, recovering an effluent stream from the deoxygenation zone. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the molar ratio of hydrogen to carbon monoxide to water in the deoxygenation zone is approximately 1:1:0.9. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein an amount of hydrogen equivalents in the deoxygenation zone comprises at least 100% of a stoichiometric hydrogen demand within the deoxygenation zone. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein an amount of hydrogen equivalents in the deoxygenation zone comprises between about 125 and 180% of a stoichiometric hydrogen demand within the deoxygenation zone. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph further comprising heating a stream of water to provide a high pressure steam, wherein the high pressure steam is passed to the deoxygenation zone. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the high pressure steam is combined with the renewable feedstock before being passed into the deoxygenation zone. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph further comprising generating a syngas stream; and, passing at least a portion of the syngas stream to the deoxygenation zone as the gaseous stream. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein a molar ratio of hydrogen to carbon monoxide of the gaseous stream comprises between 50:50 to 80:20. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein at least a portion of the gaseous stream is combined with the renewable feedstock before being passed into the deoxygenation zone. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph at least a portion of the gaseous stream is injected directly into the deoxygenation zone. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein a high pressure steam is combined with the renewable feedstock before being passed into the deoxygenation zone.

Without further elaboration, it is believed that using the preceding description that one skilled in the art can utilize the present invention to its fullest extent and easily ascertain the essential characteristics of this invention, without departing from the spirit and scope thereof, to make various changes and modifications of the invention and to adapt it to various usages and conditions. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limiting the remainder of the disclosure in any way whatsoever, and that it is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.

In the foregoing, all temperatures are set forth in degrees Celsius and, all parts and percentages are by weight, unless otherwise indicated.

While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims and their legal equivalents. 

1. A process for converting a renewable feedstock to a transportation fuel, the process comprising: deoxygenating a renewable feedstock in a reaction zone having a catalyst; passing a gaseous stream to the reaction zone, wherein the gaseous stream comprises a mixture carbon monoxide and hydrogen; and, passing water into the reaction zone to promote deoxygenation and to produce hydrogen.
 2. The process of claim 1 wherein the water is passed into the reaction zone by mixing a stream comprising water with the renewable feedstock to form a combined feed stream that is passed into the reaction zone.
 3. The process of claim 2 wherein the water comprises steam.
 4. The process of claim 1 further comprising: heating water to provide a high pressure steam; which is passed into the reaction zone.
 5. The process of claim 4 wherein the high pressure steam is combined with the renewable feedstock before the high pressure steam is passed into the reaction zone.
 6. The process of claim 1 wherein an amount of hydrogen equivalents in the reaction zone comprises at least 100% of a stoichiometric hydrogen demand within the reaction zone.
 7. The process of claim 1 wherein an amount of hydrogen equivalents in the reaction zone comprises at least 125% of a stoichiometric hydrogen demand within the reaction zone.
 8. The process of claim 1 wherein an amount of hydrogen equivalents in the reaction zone comprises at least 150% of a stoichiometric hydrogen demand within the reaction zone.
 9. The process of claim 1 wherein the gaseous stream comprises syngas.
 10. A process for converting a renewable feedstock to a transportation fuel, the process comprising: passing a renewable feedstock into a deoxygenation zone having a vessel with a catalyst and being configured to deoxygenate oxygenated hydrocarbons; passing a gaseous stream to the deoxygenation zone, wherein the gaseous stream comprises a mixture carbon monoxide and hydrogen; passing a water stream into the deoxygenation zone to promote deoxygenation and to produce hydrogen; and, recovering an effluent stream from the deoxygenation zone.
 11. The process of claim 10 wherein the molar ratio of hydrogen to carbon monoxide to water in the deoxygenation zone is approximately 1:1:0.9.
 12. The process of claim 10 wherein an amount of hydrogen equivalents in the deoxygenation zone comprises at least 100% of a stoichiometric hydrogen demand within the deoxygenation zone.
 13. The process of claim 10 wherein an amount of hydrogen equivalents in the deoxygenation zone comprises between about 125 and 180% of a stoichiometric hydrogen demand within the deoxygenation zone.
 14. The process of claim 10 further comprising: heating a stream of water to provide a high pressure steam, wherein the high pressure steam is passed to the deoxygenation zone.
 15. The process of claim 14 wherein the high pressure steam is combined with the renewable feedstock before being passed into the deoxygenation zone.
 16. The process of claim 10 further comprising: generating a syngas stream; and, passing at least a portion of the syngas stream to the deoxygenation zone as the gaseous stream.
 17. The process of claim 10 wherein a molar ratio of hydrogen to carbon monoxide of the gaseous stream comprises between 50:50 to 80:20.
 18. The process of claim 10 wherein at least a portion of the gaseous stream is combined with the renewable feedstock before being passed into the deoxygenation zone.
 19. The process of claim 18 at least a portion of the gaseous stream is injected directly into the deoxygenation zone.
 20. The process of claim 18 wherein a high pressure steam is combined with the renewable feedstock before being passed into the deoxygenation zone. 